Position Description
The Tool & Die Technician plans and performs skilled tooling operations necessary to maintain, troubleshoot, repair, modify, and improve dies, fixtures, gauges, tools, jigs, and related equipment used in an aluminum High Pressure Die Casting (HPDC) manufacturing environment.
This position is responsible for maintaining tooling in a condition that supports safe operation, product quality, dimensional accuracy, production efficiency, and equipment reliability. The Tool & Die Technician performs preventive and corrective maintenance, precision machining and fitting, die troubleshooting, and tooling improvements while working closely with Production, Die Cast Maintenance, Quality, Engineering, and Process personnel.
Job Responsibilities
- Build, repair, modify, maintain, and assemble dies, jigs, fixtures, gauges, tools, and related tooling used in the manufacturing process.
- Perform preventive and corrective maintenance on HPDC dies, including inspection, disassembly, cleaning, repair, replacement of components, reassembly, and functional verification.
- Inspect and maintain die components including cover and ejector halves, inserts, cores, slides, ejector systems, guide pins, bushings, shot-related tooling components, vents, overflows, seals, fittings, and cooling/heating circuits.
- Examine dies and tooling for wear, cracking, erosion, heat checking, soldering, damaged parting surfaces, plugged cooling passages, water leaks, damaged vents, and other conditions that may affect casting quality or die performance.
- Read and interpret blueprints, tooling drawings, engineering specifications, tolerances, and GD&T requirements as applicable to assigned work.
- Set up and operate tool-room equipment including manual lathes, milling machines, drill presses, surface grinders, and other machining equipment necessary to manufacture or repair tooling components.
- Safely operate hand tools, power tools, precision tools, grinding equipment, polishing equipment, and other equipment required for tooling maintenance and repair.
- Perform precision fitting, spotting, grinding, stoning, polishing, and finishing of tooling surfaces and components.
- Machine, modify, repair, or replace tooling components such as inserts, cores, ejector pins, guide pins, bushings, slides, and other die components.
- Verify dimensions, alignments, fits, tolerances, and clearances of dies, tooling, and replacement components using appropriate precision measuring equipment.
- Properly use precision measuring equipment including micrometers, calipers, indicators, height gauges, bore gauges, gauge pins, and other applicable inspection equipment.
- Assemble repaired or modified dies and tooling and verify proper mechanical operation prior to release to production.
- Support die installation, setup, connections, alignment, testing, and production startup as required.
- Assist Die Cast Production, Maintenance, Process Technicians, and other personnel during die changes and production startups when tooling support is required.
- Troubleshoot tooling-related production problems and determine appropriate corrective actions to restore safe and efficient production.
- Investigate die-related cause-and-effect issues involving casting defects, dimensional variation, machine downtime, and tooling failures.
- Troubleshoot tooling conditions that may contribute to flash, sticking, ejection problems, dimensional variation, incomplete fill, porosity, water leaks, and other casting defects.
- Evaluate whether production problems originate from the die/tooling, machine, casting process, material, or peripheral equipment and communicate findings to the appropriate personnel.
- Troubleshoot and repair die-related hydraulic and pneumatic components, including cylinders, core pulls, hoses, fittings, connections, and associated components.
- Inspect, troubleshoot, and maintain die cooling and thermal-control components including water lines, cooling passages, bubblers, fittings, seals, and related components.
- Perform appropriate die repair techniques, including preparation and finishing of repaired surfaces and welding-related repairs when qualified and authorized.
- Set up and test dies to verify proper function and ability to produce parts according to product and quality specifications.
- Examine existing dies, tools, jigs, and fixtures and recommend modifications to improve function, reliability, maintainability, die life, cycle performance, or product quality.
- Assist Engineering, Process, Quality, and Product Development personnel by providing tooling and manufacturing input regarding new products, tooling modifications, engineering changes, and manufacturing capability.
- Participate in root cause analysis and corrective-action activities involving tooling failures, recurring die problems, casting defects, and production downtime.
- Identify opportunities to extend die life, reduce tooling failures, reduce repair time, improve production uptime, and prevent recurring tooling problems.
- Support continuous improvement activities related to quality, cost reduction, cycle time, tooling reliability, preventive maintenance, safety, and manufacturing efficiency.
- Maintain accurate documentation of preventive maintenance, repairs, tooling changes, measurements, component replacements, identified problems, and corrective actions.
- Communicate tooling condition, repair status, recurring problems, and recommended corrective actions to Production, Maintenance, Quality, Engineering, Process personnel, and management as appropriate.
- Maintain tools, equipment, workbenches, and Tool Room areas according to established 5S and housekeeping standards.
- Follow all company safety requirements, including Lockout/Tagout (LOTO), machine guarding, stored-energy control, hot-work requirements, lifting and rigging procedures, and required PPE.
- Assist with die setting and other tooling activities as required by production and maintenance needs.
- Perform other duties as assigned by the Tooling Manager, Die Cast Manager, Plant Manager, or other authorized management personnel.
Required Skills & Technical Competencies
The Tool & Die Technician should demonstrate proficiency or the ability to become qualified in the following areas:
- Aluminum High Pressure Die Casting tooling and die construction
- HPDC die assembly and disassembly
- Preventive and corrective die maintenance
- Tooling troubleshooting and root cause analysis
- Manual machining and Tool Room equipment
- Blueprint and technical drawing interpretation
- Geometric Dimensioning and Tolerancing (GD&T)
- Precision measurement and inspection
- Grinding, polishing, stoning, fitting, and bench work
- Die repair and appropriate welding/repair techniques
- Hydraulic and pneumatic systems associated with die operation
- Die cooling, heating, and thermal-control systems
- Slides, cores, ejector systems, inserts, pins, bushings, vents, and overflows
- Die setup and production startup support
- Identification of tooling-related casting defects
- Preventive maintenance principles
- Problem solving and root cause analysis
- Lockout/Tagout and stored-energy control
- Safe lifting and rigging practices
- 5S and workplace organization
- Accurate maintenance and repair documentation
- Continuous improvement principles
Requirements
- Must be available to work and/or rotate among three shifts according to reasonable production and staffing schedules as required.
- Must successfully complete required internal qualification or certification programs applicable to assigned duties, including tooling, safety, forklift operation, and other required activities.
- Must successfully complete required 5S training.
- Must successfully complete company-required OSHA and safety training.
- Must successfully complete the company's Tool & Die Technician on-the-job training and qualification program.
- Must demonstrate effective verbal communication skills and the ability to communicate technical information clearly with Production, Maintenance, Quality, Engineering, Process personnel, and management.
- Must possess strong mechanical aptitude and the ability to diagnose mechanical and tooling failures.
- Must be capable of reading and understanding technical instructions, drawings, specifications, procedures, and work instructions.
- Must demonstrate the ability to independently evaluate tooling problems and determine appropriate repair or corrective-action methods within the scope of training and authorization.
- Must possess the ability to concentrate on detailed tasks for extended periods while maintaining accuracy and awareness of surrounding hazards.
- Must be capable of organizing and prioritizing work in response to preventive maintenance schedules, planned tooling work, and unplanned production breakdowns.
- Must be able to work effectively in a fast-paced manufacturing environment where production downtime may require timely troubleshooting and repair.
Physical Requirements
- Ability to frequently lift and/or move up to 25 pounds and occasionally lift and/or move up to 50 pounds.
- Frequently required to stand, walk, sit, use hands to handle or manipulate tools and components, reach with hands and arms, climb stairs, talk, and hear.
- Must possess the visual ability necessary to safely and accurately perform precision tooling work, including close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus.
- Must be capable of safely performing work around large dies, machinery, tooling, hot surfaces, and manufacturing equipment.
- Must be capable of using required personal protective equipment.
Work Environment
While performing the duties of this position, the employee regularly works in a manufacturing and Tool Room environment and may be exposed to heat, cold, noise, oils, lubricants, metalworking fluids, moving mechanical equipment, and other conditions associated with an aluminum High Pressure Die Casting facility.
The employee may occasionally be exposed to outdoor weather conditions when performing assigned duties.
Appropriate personal protective equipment must be worn as required by company policy and the hazards associated with the assigned task or work area.
Required Qualifications
- High school diploma or equivalent required.
- Completion of a formal Tool & Die apprenticeship program, Journeyman Tool & Die qualification, or equivalent combination of technical education, training, and relevant experience preferred.
- Associate degree in Tool & Die Technology, Machine Tool Technology, Industrial Maintenance, Manufacturing Technology, or a related technical discipline preferred but not required.
- Three (3) to five (5) years of relevant manufacturing, Tool & Die, tooling, machining, or related industrial experience preferred.
- Previous experience with aluminum High Pressure Die Casting dies strongly preferred.
- Demonstrated technical knowledge of tooling, machining, precision measurement, mechanical systems, and manufacturing processes.
- Experience operating manual machine tools such as mills, lathes, drill presses, and grinders preferred.
- Ability to read blueprints, tooling drawings, technical specifications, and dimensional tolerances required.
- Working knowledge of GD&T preferred.
- Strong troubleshooting and mechanical problem-solving skills.
- Strong organizational and communication skills.
- Ability to work independently as well as collaboratively with Production, Maintenance, Quality, Engineering, and Process teams.
Supervisory Responsibility
This position has no direct supervisory responsibilities but does serve as a coach and mentor for other positions in the department.
Work Environment
This job operates in a factory environment, with exposure to shop elements such as heat, noise, dust, fumes, and odors.
Physical Demands
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.
While performing the duties of this job, the employee is regularly required to talk or hear. The employee frequently is required to stand; walk; use hands to finger, handle or feel; and reach with hands and arms. The employee is occasionally required to sit; climb or balance; and stoop, kneel, crouch or crawl. The employee must frequently lift and/or move up to 50 pounds and occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus.
Position Type/Expected Hours of Work
This is a full-time position.
Travel
Little to no travel is expected for this position.
Other Duties
Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Pay: $25.00 - $35.00 per hour
Expected hours: 40.0 per week
Benefits:
- 401(k)
- 401(k) matching
- Dental insurance
- Health insurance
- Life insurance
- Paid jury duty
- Paid time off
- Vision insurance
Work Location: In person
